3 Alok Sharma

CNG for Clean & Green EnvironmentCNG for Clean & Green Environment 1

WELCOME to the presentation On

Safety in CNG / PNG Operations

INDRAPRASTHA GAS LIMITED

August 12th, 2010


OVERVIEW

1

SAFETY IN PNG OPERATIONS

3 SAFETY IN CNG OPERATIONS

4

ABOUT IGL

IGL INITIATIVES5

2 NATURAL GAS : COMPRESSED NATURAL GAS


INDRAPRASTHA GAS LIMITED (IGL)Incorporated on 23rd December

1998 for supply of natural gas to

domestic, commercial and

automobile sectors (CNG).

Immediate target -

implementation of Supreme Court

order

GAIL22.50%

BPCL22.50%Govt. of Delhi

5.00%Institutional

16.54%

FII17.87%

Individuals10.27%Body Corporate

5.32%


AURAIYA

DADRI

VIJAIPUR

BORERI

ANTA

(OFCL)SHAHJAHANPUR

(IFFCO) AONLA

TCL-BABRALA

MATHURA

AGRA/FEROZ

DESU/Delhi/MARUTI

FARIDABADNTPC DADRI

CFCL

DAHEJ

HVJ PIPELINEDESIGN CAPACITY:33.4 MMSCMDDESIGN PRESSURE:92 KG/SQ CM

LENGHTH:2800 KMS

EXISTING LINE

JAGDISHPURNTPC AUR

NEW LINE36”*640 km Existing HBJ Additional Compression

Hazira VAGHODIA JHABUA

KHERA

42”*610 km

CHAINSA


Geographical Spread in DelhiAT PRESENT IGL IS OPERATING MORE THAN 3000

KMS OF PIPELINE NETWORK IN DELHI & NCR


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4

ABOUT IGL

IGL INITIATIVES5



NATURAL GAS

• A MIXURE OF HYDROCARBONS

• TYPICAL COMPOSITION FOR NG

METHANE (CH4) : 85-90%

ETHANE (C2H6) : 5-7%

PROPANE (C3H8) : 2%

CARBON DI-OXIDE : 3-5%

OTHERS : 1%

SPECIFIC GRAVITY: : 0.65 (Approx)

• CALORIFIC VALUE (net) : 8300 KCAL/SCM


Compressed Natural Gas (CNG)

• Natural gas is compressed to 250 Kg/cm²g through reciprocating compressors installed at Mother and On-Line CNG Stations for use as automotive fuel.

• CNG is dispensed to vehicles at maximum 200 Kg/cm²g pressure.

• CNG is artificially odorized(Ethyl Mercaptan)

• Physical Properties of CNG:• Colourless• Non-toxic• Lighter than air• Non-corrosive


COMPARATIVE PROPERTIES OF AVAILABLE FUELS

CNG : AN INHERENTLY CLEAN & SAFE FUEL

PROPERTIES UNIT PETROL DIESEL CNGCALORIFIC VALUE

KCAL/KG 11200 10850 10600

RELATIVE DENSITY

AIR=1 3.4 3.9 0.65

AUTOIGNITION TEMPERATURE

ºC 232-282 225 540

FLAMMABILITY LIMIT

% IN AIR 1-8 0.6-5.5 5-15

FLAME TEMPARATURE

ºC 1977 2054 1790


CNG Compressor

Storage Cascade

Dispenser

CNG Vehicle

Mobile Cascade

Mobile Cascade

Mobile Cascade

Booster

Dispenser

CNG Vehicle

Mobile Cascade

Dispenser

CNG Vehicle

CNG Compressor

Storage Cascade

Dispenser

CNG Vehicle

19-22 Kg/cm2g

250 Kg/cm2g

<=200 Kg/cm2g <=200 Kg/cm2g

<=200 Kg/cm2g<=200 Kg/cm2g

19-22 Kg/cm2g

250 Kg/cm2g

STEEL PIPELINE – NATURAL GAS CARRIER

CNG SUPPLY CHAIN

MOTHER STATION

DAUGHTER STATION

ONLINE STATION

DAUGHTER BOOSTER STATION


CNG PROJECT OF DELHI & NCRSTATUS

NO. OF STATIONSMOTHER : 1 88ONLINE : 3 58DAUGHTER : 5 01

DAUGHTER : - 47BOOSTERTOTAL : 9 195 244

COMPRESSION CAPACITY : 0.02 3.11 4.25(MILLION SCM/DAY)

NOS. OF CNG VEHICLES : 1200 0.35 million(APPROXIMATELY)

AVERAGE CNG SALE,(MILLION SCM/DAY) : 0.003 1.95 2.3

PILOT PHASE(END ‘98)

PRESENT(July’(July’10)

FUTURE(till 2012)


Delhi-CNG Infrastructure

• Buses 14,764 100%

• Auto 1,10,245 100%

• RTV’s 17,474 100% & Taxi’s

• Private 2,11,313 10%Cars

The present infrastructure caters to more than 3,50,000 vehicles from NCT Of Delhi and NCR. This includes the largest fleet Of CNG buses operated in any single city in the world


Growth / Projection of CNG Stations

153 16

3 179 19

4

217 24

4

0

50

100

150

200

250

2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

No.

of C

NG

Sta

tions


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4

ABOUT IGL

IGL INITIATIVES5



DESIGN & OPERATIONAL SAFETY OF

CNG STATIONS


• The CNG Stations are designed as per Best National & International Codes and Standards.


SALIENT FEATURES OF COMPRESSORS

TYPE RECIPROCATING.CAPACITY 250 – 1200 SCM/HR.DISCHARGE PRSSURE 255 KGS./CM2GDESIGN CODE API-11P, OISD 179, NFPA-37,

ANSI, ASTM, NEC, NEMA,INDIAN ELECTRICITY RULES ANDINDIAN EXPLOSIVE ACT.

PRIME MOVER GAS ENGINE / ELECTRIC MOTORSAFETY FEATURES PLC CONTROL WITH ALL

SAFETY INTERLOCKS, CO2FLOODING SYSTEM,LEL DETECTORS, UV/INFRAREDFLAME DETECTORS ANDESD SYSYTEM


PLC CONTROL

● The unit is designed for fully automated, unattended operation.

● Auto start, auto stop, alarm & trip on development of abnormal condition through PLC control.

● The unit goes into a safe mode in case of any fault.


SAFETY INTERLOCKSSafety interlocks are provided in the PLC system to give Audio-Visual alarm & trip the unit whenever any of these parameter crosses the High/Low limits :

• High Discharge Pressure : Each stage• Low Pressure : Suction, Engine Lube Oil, Compressor

Oil• High Temperature : Each stage, Lube Oil, Coolant• Gas Leakage in the Package• Flame• Low Level : Lube Oil, Coolant• High Vibration


LEL & FLAME DETECTORS

• 2 Nos of L.E.L. Detectors in each partition of the package provided to sense gas leakage

• 2 Nos of UV / IR flame detectors provided in each partition of the package to sense Flame.

• The signals of each of these sensors are continuously monitored by the PLC system. Upon sensing presence of Gas or Flame, the PLC trips the unit, and isolates it from suction line, CNG dispensers & the cascades.

• In case a flame is sensed, the CO2 Flooding system is activated to immediately extinguish the fire.


GAS DETECTOR INSIDE CNG COMPRESSOR


FLAME DETECTOR INSIDE CNG COMPRESSOR


CO2 FLOODING SYSTEM

• The compressor package is provided with a CO2 flooding system, which is triggered by signal from the UV/IR flame detectors.

• On detection of flame, CO2 is Discharged to extinguish the fire.


IGNITION SYSTEM

• The Natural Gas Engine is provided with a Breaker-less Ignition system. There is no distributor in the system, which might be a potential source of spark.

• All the wiring harness of the Ignition system are enclosed in grounded, metal shielded flexible conduits, thus any leakage current does not generate spark.

• The Ignition transformers are mounted on the spark plug, avoiding any high tension cable.

• Engine Silencer is Residential / Hospital type with Exhaust Flame trap and Spool type Flexible Connector.


ESD SYSTEM

• The CNG compressor packages are provided with an Emergency Shut Down System.

• The ESD system is activated by pushing a Mushroom Head type Emergency switch mounted in a safe & accessible location.

• The ESD system, when activated,• Brings the unit to an immediate halt.• Isolates the unit from Gas Suction Line.• Closes all the output priority valves, thus

isolating the Compressor, Cascades & Dispensers from each other.


ELECTRICAL CONNECTIONS

• All the Cables are terminated with Double compression Explosion - proof glands.

• The Electric Motors are Explosion Proof, with Motor Protection relays, with Multiple safety features.


INTRINSICALLY SAFE

• All the instruments / sensors are intrinsically safe, suitable for hazardous area application.

• Any Loose Wiring / Failure of any sensor / instrument takes the PLC to fail safe mode.


SALIENT FEATURES OF CASCADES

• TYPE 3000 WATER LITRE CAPACITY2200 WATER LITRE CAPACITY

• NO OF BANKS 3 OR 1

• DESIGN CODE• CYLINDERS GAS CYLINDER RULES & IS: 7285• VALVES IS: 3224• SAFETY DEVICES IS: 5903

• OPERATING PRESSURE 255 BAR

• TEST PRESSURE 435 BAR


SALIENT FEATURES OF CASCADES

• SAFETY FEATURES

• PRESSURE RELIEF DEVICES ARE PROVIDED IN THE FORM OF BURST DISCS WITH FUSIBLE PLUG, TO RELEIVE THE EXCESS PRESSURE.

• THE VENT OF RELEIF DEVICES OF INDIVIDUAL CYLINDERS IS COMBINED INTO A COMMON MANIFOLD & RELEASED TO ATMOSPHERE AT A SAFE LOCATION.

• CNG CYLINDERS ARE HYDROTESTED EVERY 5 YEARS.


SALIENT FEATURES OF DISPENSERS

CAR DISPENSERS

• TYPE FAST FILL• NO OF ARMS 2• FLOW RANGE 0-15 KG/MIN• DESIGN CODE NFPA 52, NGV 4.2/A.G.A. 1-93,

ANSI/NGV1,NGV 4/A.G.A., AG901,IS 5572, IS 5571, OISD 179 AND OISD 113

• SAFETY FEATURES OVER FILL PROTECTION, ESD MANUALVALVES, BREAK-AWAY COUPLING WITH

AUTO CUT-OFF DEVICEEXCEEDING 200 KG/CM2.


SALIENT FEATURES OF DISPENSERS

BUS DISPENSERS

• TYPE ULTRA FAST FILL• NO OF ARMS 1• FLOW RANGE 0-75 KG/MIN• DESIGN CODE NFPA 52, NGV 4.2/A.G.A. 1-93,

ANSI/NGV1, NGV 4/A.G.A., AG901,IS 5572, IS 5571, OISD 179 AND OISD 113

• SAFETY FEATURES OVER FILL PROTECTION, ESDMANUAL VALVES, BREAK-AWAY COUPLING WITH AUTO CUT-OFF DEVICE.


CONDUCTIVE HOSES & EARTHING

• The filling Hoses of CNG Dispensers are Electrically Conductive & designed as per ANSI / NGV 4.2

• Static charge is carried to dispenser body, and does not produce spark during engagement and disengagement of Filling nozzle with Vehicle receptacle.

• The dispensers are Earthed to dissipate the Static Charge, and leakage current if any.


STATION TUBING & FITTINGS

• All the High Pressure Tubing at CNG stations is made of Stainless Steel, which does not corrode.

• All the tubing Connections are Double Ferrule type.

• All tubing & fittings are procured from internationally reputed vendors.


INTER DISTANCES (FROM BUILDINGS AND

OUTER BOUNDARIES TO GAS STORAGE)

S.NO. TOTAL CAPACITY OF GAS STORAGE UNITS (IN LTRS.)

MINMUM DISTANCE FROM BUILDINGS AND BOUNDARIES (IN

MTRS.)

1 UPTO 4500 2.5

2 4500-10000 4.0

3 10000-100000 10.0

SOURCE: OISD - 179

TABLE-1


INTER DISTANCES (BETWEEN VARIOUS FACILITIES)

S. NO.

DISTANCE FROM (IN MTRS.)

1 2 3 4 5 6 7

1 CNG COMPRESSOR - 3 2 3 6 6 T-1 (MIN-3)

2 CNG DISPENSING UNIT 3 - 2 4 6 4 -DO-

3 STORAGE CASCADES 2 2 - T-1 T-1 (MIN-6)

T-1 (MIN-4)

-DO-

4 OUTER BOUNDARY WALL/CLF

3 4 T-1 - 6 4 -DO-

5 MS/HSD DISPENSER 6 6 T-1 (MIN-6)

6 - 6 -DO-

6 VENT OF MS/HSD U/G STORAGE TANKS

6 4 T-1 (MIN-4)

4 6 - 6

7 FILLING POINT OF MS/HSD

------------------T-1 (MIN-3)------------------- 6 -

TABLE-2

T-1 STANDS FOR TABLE-1 SOURCE: OISD - 179


FIRE PROTECTION SYSTEMAT CNG STATIONS

A) FIRE FIGHTING ARRANGEMENTS AS PER OISD-179:

EQUIPMENT DCP-75KG. DCP-10 KG. CO2- 4.5 KG.

COMPRESSOR 1(online & mother)

1 -

DISPENSER - 1 -

CASCADE - 1 -

LCV POINT - 1 -

ELECTRICAL PANEL - - 1


FIRE PROTECTION SYSTEMAT CNG STATIONS

B) AS PER CCOE GUIDELINES: 6 NOS. FIRE BUCKETS AT EACH CNG STATION.

C) ADDITIONAL SAFETY MEASURES BY IGL:

CO2 FLOODING SYSTEMS FOR COMPRESSORS ARE INSTALLED AS STANDARD SAFETY MEASURE.


SAFETY PRACTICES IN O&M

• Preventive Maintenance of Equipment

• Regular Testing and Calibration

• CNG is odorized for easy detection in case of leakage

• Portable & fixed Gas Detectors for Checking Leaks

• Compressor Area Fenced

• Installation of Safety Guards for Dispensers

• Safety & Operational Training to all staff

• Safety Manual with all safety & emergency information.

• Safety Work Permit System followed.


SAFETY PRACTICES O&M contd.

• Display of Safety Film on CNG.

• Use of required Personal Protective Equipment

• Safety Committee for worker participation.

• Safety Audit / Safety Inspection conducted.

• Accident Reporting, Recording, Investigation & Analysis

• Safety Awareness and Campaign conducted.

• CNG refueling is done with no passengers in the vehicle

• Ignition keys of vehicles are removed before refueling


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ABOUT IGL

IGL INITIATIVES5



CGD Line Diagram

City Gas Station

District Regulating

Station ( DRS )

Regulating / Metering

Kitchen BurnerG.I. / Cu Piping

21 mbar

CNGDispensing

200 Bar M.D.P.E4 Bar

Transmission Gas HVJ Pipeline ,

Pressure - 60 bar

Steel Pipe NetworkPressure 19 to 26 Bar


Geographical Spread in DelhiAT PRESENT IGL IS OPERATING MORE THAN 3000

KMS OF PIPELINE NETWORK IN DELHI & NCR


PNG Segment (Number of Connections)

• Domestic Connections – 1,85,300

• Commercial Connections – 361

• Industrial Connections – 31

• Total PNG Sales – 0.28 MMSCMD

• Planning 3,35,000 domestic connections by 2011-12


PNG - A Typical Gas Supply Scheme


FEW OF THE SATISFIED CUSTOMERS

AKSHARDHAM TEMPLE


Safety Systems & Arrangements for PNG Safety Systems & Arrangements for PNG DistributionDistribution

• Pipeline is laid 1 meter below ground level.

• Warning tape with emergency contact nos. laid above 250mm the Pipeline.

• Above ground Pipelines markers with emergency contact nos. is installed.

• Round the clock Pipeline patrolling is done by Security guards.

• Isolation valve every 2 kms or at branch of 63mm size pipeline.


Safety Systems & Arrangements for Safety Systems & Arrangements for PNG DistributionPNG Distribution

• Regular Safety Clinics are conducted in the societies for educating consumers.

• All the PNG contract & IGL employees are imparted with regular Fire & Safety Training with live fire fighting experience of gas fire.

• Proper Personnel Protective Equipments are provided to the PNG workers for the safe execution of the job.

• Cautionary instructions and Safety pamphlets bearing emergency contact numbers are distributed regularly along with the bills for enhancing safety awareness to the consumers.

• Safety Kits and liveries (Safety Clothing, Shoes etc.) are provided to IGL employees as well as contract staff on yearly basis.


Safety Systems & Arrangements for Safety Systems & Arrangements for PNG DistributionPNG Distribution

• Portable gas detectors for monitoring gas leak and First Aid box for staff is provided at the PNG control rooms as per statutory requirements. Calibration and testing of gas detectors is done on half yearly basis.

• External Safety Audits of all the Small, Medium and Large commercial establishments like restaurants, hotels, hospitals & industries where gas is distributed by IGL, are carried out by Internationally accredited third party or agency and its compliance is ensured.

• Safety Committee Meetings are held at Control room level with equal participation of executives and non executives, to address all the safety related issues and implementation of safety policies. Central Safety Committee Meetings are conducted on yearly basis.

• HAZOP and Risk Assessment studies of CNG equipments & installations are carried out from time to time by Internationally accredited third party.


PIPELINE ROUTE MARKERS

PLATE MARKER

CONCRETE MARKER

POLE MARKER


Consequences of Gas Leak & Fire at

CNG Station due to Consumers’ Vehicles


View of totally damaged CNG

Station


Cause: Fire due to Safety Disc Failure


(Safety Disc)

Failure of Safety Disc of CNG Cylinders results in High Pressure (up to 200 kg/cm2) Gas Leak resulting in damage to vehicles as well as CNG

station


Unprotected Battery Terminals and Improper Wiring in CNG

Vehicles

Cause Fire due to Short Circuit


Unprotected Battery Terminals and non-standard wiring


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ABOUT IGL

IGL INITIATIVES5



DCP SYSTEM DESIGNED AND INSTALLED TO

AVOID OCCURANCE OF FIRE DUE TO SAFETY

DISC FAILURES RESULTING IN MAJOR FIRES.

IGL’S INITIATIVE TO MITIGATE INCIDENCES



STATIONS EQUIPPED WITH STATIONS EQUIPPED WITH LARGE CAPACITY DCP LARGE CAPACITY DCP SYSTEM FOR ATTENDING SYSTEM FOR ATTENDING BUS FIRE AT CNG STATION.BUS FIRE AT CNG STATION.


• Training is given prime importance and regular trainings are imparted to IGL employees, Contract workers, CNG & PNG consumers, Security Guards and Delhi Fire Service personnel.

• Multi-discipline Core Safety Groups trained from NEBOSH, UK ensures implementation of Safety Management System in CNG and PNG - O&M.

TRAINING



Fire & Safety Training to IGL Fire & Safety Training to IGL EmployeesEmployees


Live Fire Fighting TrainingA Demo site has been developed at Rohini Fire Station and live fire fighting training is imparted to IGL Employees, Station Staff and Consumers.


Live Fire Fighting Training to DTC staff


Fire & Safety Training to Security Guards


Fire & Safety Training to CNG Station Workers


Station staff is regularly trained and mock drills are conducted


CNG Fire Training to Delhi Fire Service Personnel


Educating CNG Consumers

Safety Clinics are regularly conducted for Consumers


FOR THE SAFETY OF SCHOOL CHILDREN

• TRAINING IMPARTED TO BUS DRIVERS AND OPERATORS OF CNG SCHOOL BUSES REGULARLY.





Random Safety Checking of Vehicles

• The CNG Vehicles are randomly checked for any gas leakage and other statutory compliances and observations are forwarded to concerned departments like DTC and Department of Surface Transport.


FREE CHECKUPS OF CNG CARS


EDUCATING CONSUMERS

Free Service Camps are conducted to

check the fitness of CNG vehicles and

creating awareness for conservation of

gas, among consumers by

educating them and pasting cautionary

instructions on their vehicles.


ACHIEVEMENT

• As a result of Management Commitment to Safety, dedicated Team-work and strong Safety Management System, IGL with more than 3000 kms pipeline network in Delhi & NCR, operating 24X7 with more than - 200 CNG stations, 3.5 Lac CNG vehicles and around 2.0 lacs PNG consumers, the company has crossed 60 Million Man Hours without any Reportable Lost Time Accident.


Thanks

Documents

3 Alok Sharma